Method of producing strip material



Jan. 27, 1959. J. B. BRENNAN METHOD oF PRoDuoING STRIP MATERIAL 2 Sheets-Sheet 1 Filed Dec. 4, 1952 F/G. Z

.Mull

INVEN TOR. JOSEPH B. BRENNAN ATTORNEYS Jan. 27, 1959 Filed Dec. 4, 1952 J. B. BRENNAN METHOD OF PRODUCING STRIP MATERIAL 2 Sheets-Sheet 2 92 F IG. l2

INVENTOR. JOSEPH B4 BRENNAIN ATTORNEYS United States Patent O METHOD oF PRoDUcrNG lSTRIP MATERIAL Joseph B. Brennan, Cleveland, Ohio; Helen E. Brennan, executrix of the estate of said Joseph B. Brennan, deceased Application December 4, 1952, Serial No..324,020

9 Claims. (Cl. 92--41) This invention relates to the production of strip ma-v terials, and especially to strip material and methods of producing continuous strips of materials suitable for use as electrodes and spacers in electrolytic condensers, batteries, or the like, and wherein preferably heat-resisting insulating refractory fibers, such as those made from glass or quartz, are bonded together by a suitable medium and then have a coating of metal applied onto one or both surfaces of the refractory fibrous strip.

Heretofore, the strips for useas electrodes and spacers in electrolytic c-ondensers or the like have been made in various manners. Paper base strips have been used in some instances, and porous metal coatings have been spray deposited thereon in one well known method for making this kind of electrodes. Various other processes for producing the electrodes have heretofore been suggested and I have found that one type of fibers which have desirable properties for use in forming electrodes of this type are refractory fibers, and especially various types of glass or quartz fibers or alumina silica fibers. When attempting to make a refractory fiber paper or mat, it has been difficult to obtain a bond between the fibers in order to produce sufficient interlock and bond between adjacent fibers so as to produce a strong selfsupporting fibrous mat or sheet therefrom. It will be understood that ksuitable fiber sheets of this type should be very thin, such as approximately .001 inch to .005 inch in thickness.

Accordingly it, has been very difficult to produce continuously, heretofore, any type of refractory `fiber strips when using vitreous or ceramicfibers in making up the strips and have the resultant strip used in the production of electrodes or as` dielectric spacers.

The general object of the present invention is to provide a new method of continuously producing dielectric conductive strip material suitable for use in the production of electrodes of the class referred to hereinabove.`

Another object of the invention is to continuously produce a porous'electrode strip using refractory fibers as a component therein and/or thereabout, and wherein such fibers are bonded together by a suitable medium, such as coherent metal particles. p

Yet another object of the invention is to continuously produce a unitary strip which can be used as a dielectric layer alone, or around ametal layer, or as a conductive layer with dielectric thereover, or as a layer which is conductive on one side and non-conductive on the other side.

A further object of the invention is to deposit or build a layer of refractory fibers which has metal particles distributed throughout the refractory fibers in conductive relationship and with the resultant sheet of material be.a

`ing adapted to be subjected to a sintering operation and/ or to an induction heating action by which the metal particles can be fused sufficiently to aid in bonding the refractory fibers to each other to produce a self-supporting conductive strip therefrom. A

2,870,689 Patented Jan. 27, 1959 ice The foregoing and other objects and advantages of the invention will be made more apparent as the specification proceeds.

For a better understanding of the invention, reference should be had to the accompanying drawings, wherein:

Fig. 1 is a vertical section of representative apparatus for practicing one embodiment of the method of the invention;

Fig. 2 is a fragmentary, enlarged section on line 2-2 of Fig. l;

Fig. 3 is a vertical section of diagrammatically illustrated apparatus for practicing a modification of the metho-d of the invention;

Fig. 4 is a fragmentary, enlarged section on line 4-4 of Fig. 3;

Fig. 5 is a'section through additional apparatus for practicing yet another method of the invention;

Fig. 6 is a fragmentary, enlarged section through a tubular eletcrode structure on line 6-6 of Fig. 5, made in accordance with a method of the invention; and

Figs. 7 through 11 are all enlarged, fragmentary sections of modified electrodes of the invention.

Fig. l2 is` another apparatus for practicing a modification of the method of the invention.

One method of the invention comprises providing a suspension of refractory pulp fibers and metal particles, depositing refractory pulp fibers and metal particles into a method or strip structure, heating the metal particles inthe matted fiber and particle structure to fuse the metal particles which when cool bond the refractory fibers together into a self-supporting fibrous strip, and rolling the self-supporting fibrous strip upon a storage reel or otherwise processing the strip so produced.`

In a modification of the method of the invention, the fibrous material deposited upon a foraminous drum or otherwise formed into a mat, may have longitudinally extending reinforcing filaments and/or cords present therein, and the fibrous material with or without reinforcing cords therein can be bonded together by means of spray-deposited molten metal particles which cool in contact with fibers to bond them together and with the fibrous mat being either preheated or cooled, as desired, so that the deposit of metal placed thereon can either be cooled immediately upon contact with such fibers, or may be thermally aided in penetrating into and bonding the fibrous mat, as desired.

One embodiment of apparatus for practicing one method of the invention is shown in Fig. l and it includes a suitable container or tank 1 in which a suspension 2 of refractory pulp fibers 2a is positioned. Additionally, usually metal particles 3 may also be present in the suspension of the fibers 2 with such suspension normally being provided in a suitable fluid, such as water, although an air suspension of the material may be used. The suspensi-onl usually is agitated by conventional means such as a plurality of propellers 4 present. in spaced portions of the suspension 2. The propellers 4 usually connect to drive motors 5 by means of shafts 6 so that the propellers 4 will be rotated rapidly to aid in maintaining a substantially uniform suspension within the tank 1.

The deposit of the fibers 2a and metal particles 3 into a continuous strip is aided or produced by the use of a suitable screen-covered or porous ceramic drum 7, such as is used in conventional paper-making apparatus. This drum 7 usually is journaled upon a tubular shaft 8 in a conventional manner and suitable means (not shown) are provided for rotating the drum 7 at a desired rate so that a continuous strip or mat of the material can be built up on the drum 7 contacting the suspension 2. Preferably, suction is used to aid in depositing the material on the surface of the rotating drum 7 so that a fibrous material vl't'ev'ayi`11g Asuspension 'can bedried prior tofurt'lier f processing thereof.

A ofthe drum 7.

The fibrous material deposited "upon 4the periphery of the drum 7,` belowl the surface.of'theususpension 2ii'a/'y be 'bonded together to form a self-'supporting "strip suitable meansLs'ucwhas a high frequency inductionhea'tidg e911 (121W jrhj y "jou 172 ils positioned djaceht the periphery 'ofthe drl'lri 7 as "it lnves fr'o-rrlthe suspension 2 andyisconnected to a suitable sdlirc'eoffhigh frequency lec'trieal eiiergy s'th'at tti'ental particles 3, deposited with the refractory'lfiberls 2q on the surface of the drum ried jandf'sintered or fusedso that the metal as they'cool will fbonfd themselves and will 'bind the varroiis fibers 'ftdgefhe'r to aid informingacontinuous :stripor'sheet 13 from tbl'ievbers andirie'tal particles. The rticles `3fi`r1 qthe `strip will fusey ytogether to 4forth structure, as theyare present lin the fibrous strip kin conta ng ;r'elationjto'each other. Y

A fsuitable' kdeposit 2 of spraydepofsitedfnfetal may lalso be deposited on the strip J1;3b'yfaconventional lnietal spray ""1 t" 's 'fd metal'has'soli'dified'it strength- -Preferably, theirf'rarctory `fibrous pulp material @used inV the practice the invention are made from glass, qilartzor eer'riiic'fbersi'and 'a -high"melting temperature glass vvvfliienis 'sbstatially'free `fromirofr1"or lead is preferably employed. l'The 4vitreous fibersshould lave 'averagediametersnotgierater lthan about .0005 inchfand the bers'rnaybe Vo'fsiiit'able length `:.suchf' Vsfr'om about 3&0 of an inch to lpinchin lengthjbrl'onger. The glasses used in making *the fibeglassrnayfbe composed princ-ipallylof oxides "of 'sili'cohfborn'-andaluminum, and

are'"res`i`stant 't'crthefaF lon ofielectiolyt ver `long periods ottime. .'Borosilicate'jfglassfbers,la rnina'l-silica-fbefsi,

Vmg l temperature ceramicfib'ers'-mybeiise Y n tleA fiberssed in th'epractice of fthe 1nv t Y'Wlien-neal'particles aeusedin the fibrous pulpsuspension,suehparticles are preferably ofone to ten*r'rlic'froiis`in'idil n sion. The inventi'on is adapted: for usewthlo'w fmeltingupoint metals, such 'as aluminum, but Vrnay'alsobe d wi`th"ve'r'y fhigh melting'4 point metals, such as "titanium and nick V`nd iron, since theseiibers'will'withstand tem ea'tur 2300 F. wthoutlos theirpeanentvstrength.4 Y

'In 'one specific eitamplleofa "vitreous" fiber-"pulp suspensionused `in Vthe Ypractie of theinvwt approximately one ounce of vgl'asslfibersand "oneou efdff' particles (aluminum) 'were "present l'per'ga'lln *of if-wafer in the suspension 'providedl and vthis"'resulted"in, thedeposit of a'desired fibrous' niet upon't'heformingdrmf. A modified method ofthe invention `is"-sl`iown iin; Fig. 3 wherein ka tank 20 is shown which hasa 'suspension 21 of refractory :fibrous :material therein, and wherein ya plurality oflongitudinally -extending parallel positine'd textile cords or filaments22 are provided to bembedded quartz glass gbers, "and 'other yhigh ,de

the fibrous strip to be produced. TThese cords 22 may 'be carried 'by one vror'more 'suitablerolls ZSadjacentthe f tank 20. A drum 24, like the drum 7 referred to hereinbefore, is provided and is rotated slowly through the suspension 21 with about 1/3 of the periphery of the` drum 24 being below the surface of the suspension 21 at any given time. This suspension 21 has dielectric ceramic fibers thereinI and may havetmetal particles or other stable particles etherein, as 1desired, for `use in bonding, the fibers deposited 4upon the surface of the drum -2'4 together after such `deposited fibers and 'the mat made therefrom are moved out from 'below rvithe surface of the suspension 21. wSuitable heating'wrneans, such s a high frequency coil 2'5, e'p'ro'vided "adjacent Upon the strip 28,"t may"neXtvfpss"foveraguidefifoll 29 drum 24 or the surface of the strip 27 exposed to thei's- I d iris tank 31 be applied to the initial fibrous surface of the strip 27, as shown in Fig. 3.

Yet ano-ther modified type of apparatus of the invention is shown in Fig. 5 which apparatus is adapted to perform another modified method of the invention. This apparatus is adapted to produce a continuous tubular product which may be a composite fabric, a conductive strip material, a tubular fibrous dielectric sheet, or a composite conductive member with fibrous insulation thereon. A plurality of fibrous textile cords 41 are led from suitable `reels or bobbins to pass over guide sheaves or pulleys 42 and into a bore 43 of a foraminous or perforate sleeve 44 at circumferentially spaced portions thereof. The sleeve 44 may be made from porous ceramic or metal or other suitable material and sufficient cords 41 are provided to position them in closely spaced relation within the bore 43. A stopper 45 is positioned in the bottom of the bore 43 to retain an aqueous fibrous suspension 46, like the suspension 3, within the bore 43. Such fibrous suspension 46 is supplied by a tube 47 that extends through the stopper 45 and connects toa suitable source of the suspension. The cords 41 are pulled past the stopper 45 which permits free movement of the cords and suction is set up on the foraminous sleeve 44 by a suitable vacuum pump 48 connected to a chamber 49 having a wall 50a in which the foraminous sleeve is positioned to aid in depositing fibers on the cords 41. The chamber 49 may be sealed around the ends and outer surface of the sleeve l44 if desired. Sufficient-fibers, or fibers and metal particles, are accreted on the cords 41 to build a tubular structure therefrom. The sleeve or former 44 is, for example, electrically heated to dry the cords 41 and fibers as they move along the sleeve and pass from the sleeve 44. A spray head 51 is positioned within the foraminous sleeve bore 43 by a conduit 52 so that molten metal or metal powder such as aluminum, for examp1e,`may be sprayed onto the cords and fibers to provide a tubular strip or structure 53 which has a porous conductive metal inner layer. The spray head 51 may be a centrifuge, if desired, and the conduit 52 then would be rotated by conventional means. One suitable centrifuge of such type isshown in my co-pending application Serial No. 318,616, filed November 3, 1952, now Patent 2,816,826.

The fibrous suspensio-n 46 may also be centrfugally deposited-with or without metal particles therein on the travelling cords 41.

Fig. 6 shows an arc of the structure S3 which has the longitudinally extending cords 41 therein with fibers 54 fro-m the suspension 46 forming a layer therewith. A porous metal inner layer 55 bonds the fibers and cords together as such metal penetrates into the fibrous layer to solidify therein and form a composite structure therewith. Suitable means (not shown) pull the structure 53 from the sleeve 43 at a desired rate.

The foraminous sleeve 44 and associated apparatus may be longitudinally split and is suitably secured together' to provide a sealed structure the parts of which can be disassembled for repair or cleaning purposes.

Any suitable molten material may be deposited by the spray head and aluminum or nickel or titanium usually would be deposited when making an electrode of the class described while plastics or/and resins may be used if dielectric sheet or tube is to be produced. Wires may be used in place of some or all o-f the cords 4l, if desired.

High frequency electrical heating means 100 may surround the conduit 52, which may be made from a ceramic, to maintain the temperature of the molten material therein, if desired. K

Themember 53 may be used when in tubular form, or

it may be split longitudinally, or it may be collapsed upon itself, as desired. t

The tubular structure 53 when liattened would retain the metal layer on the interior thereof to make an insulated, conductive condenser material for use in either electrolytic, or electrostatic con-densers. By slitting the tubular structure 53 longitudinally, it can be flattened to be used as a composite electrode and separator strip, as desired.

In practicing the method disclosed in Fig. 1, it may be desirable, in somel instances, to apply a more protracted heating action than is indicated in Fig. 1, and a heating chamber may even be associated with a portion of the periphery of the drum 7 to give a sintering action on the metallic particles 3 included in the fibrous mat built up or accumulated upon the surface of the :screen drum 7. Thus, a self-supporting, strong strip of material could be Ibuilt up on the drum 7 merely by use of the glass fibers and metallic particles originally deposited as a mat on the drum, wherein the metallic particles are present in sufficient quantity, to bond the matted fibers together.

It also is possible to use'the method of Fig. 1 when higher melting temperature metallic particles are used in the suspension 2 than the low melting metals set forth hereinbefore. Thus, small particles of nickel, iron or titanium may be used in the suspension 2 and then the mat produced usually should be subject to high frequency electrical induction heating thereafter, as such type of heating effectively renders the metal particles in the fibrous mat sufficiently sintered or fused that they would bond to the glass fibers to secure such fibers together into a strong, self-supporting mat for use as an electrode of the type referred to hereinabove. The induction heating does not affect the glass ceramic fibers in the maty in an injurious manner. Then when such metal particles cool and solidify, the glass ceramic fibers are still in contact with the sintered or fused metal particles so that a desired bonding action is obtained. The strip material so produced` m-ay be further built up by a sprayed-metal layer deposited thereon, as desired.

In some instances, it may be desirable.` to use suction action on more of the periphery of the drum of the apparatus than is indicated in the drawings and has been referred to before.` Thus, a suction action may be set up within the drums at the zone thereof at which sprayed metallic substances, or other materials, are being deposited upon the fibrous mat on the drum surface. Of

- course, if desired, the rolls 27 referred to as the cooling rolls may in some instances have heating fluid supplied thereto so that such rolls would give a heating action upon the fibrous mat on the surface of the drum contacted by such rolls when the temperature of such mat is to be elevated prior to deposit of other material thereon.

In the spray depositof metallic particles in accordance Wtih this invention, and especially in the methods disclosed in Figs. l and 3, it may be desired to superheat the metal particles in transit, and such action may be secure-d by the use of high frequency coils placed in encompassing relation t-o the sprayed metal particles in transit. Furthermore, the sprayed metal particles may be bounced off heated rotating discs placed adjacent the periphery of the screened drums to aid in heating such metal particles and thereby obtaining a vaporization of the metal in transit to further finely divide the metal particles prior to deposit upon the fibrous mat on the surface of the drum.

The invention also could be practiced by the spray deposit of thermoplastic dielectric materials, such as polyvinyl chloride, vinylidene chloride, or urea-formaldehyde compounds, for example, by the spray nozzle 36 shown in Fig. 3 so that such dielectric material would reinforce and aid in insuring the production of a dielectric sheet or film upon one surface of the strip material produced. After an electrode strip of the invention has thermoaaa-romeo T7 plasticmaterialsfdeposited1 thereon, i'tfma'y fbe desired to cool such strip .of material by exposure-tothefatmos# phere before it ispnlledrfrom'itsfsupport; or byf a-.rpositive-cooling action prior to' 'moving' fthe' strip so `produced from-the surfaces of-the'screen-drum-.

Reference now vis particularly directedf'to .the crosssectionsl of typical types ofelectrodes* and 'dielectric separa'tors o'r similar" articles'-that'\rnay 1 be; prepared A'by :the processes of the invention. Thus, in Fig. 2 a strip `1?: 'fis sliown"whic`h has a conductivel yporous metal -l'ayer-'60 on one surface thereof, i whereas the fmetfal `particles 3 in' the original vsuspensiomz h'ave beenffused together tobi-nd a.- por`os, Yconductive* zmetal body61 inthe electrode l13 'and with` a plurality I"of fthe; glass or fother fceramic'fiibe'rs 2a being1heterogeneouslyf-positioned With-'and intimately bbndedtoatherfrrnetalf-body-*61.Y Tn Fig.; 4,` the electrodeY 35 iis-shownand itrhasfa porous metal layer" 62 on each outer surfacethereof iproduced! bythe spray-depositwof vrnol'tenf aluminum, for example, on "the base-strip provided. Thefreinforcing-cords-22amclearly shownl in Fig. 4," l'which v brings 'out the" preferred lateral-spacing of lsuch cords with rela-tion to eachother.

The `cords'\22 Amay' bemade from any 'suitable textile material such 'as cotton, orfglassfor ceramic-filaments or fibers. If -metaf'particl'es arepresentin'the originali-sus- `pensions 21 and "31 vfrom which the electrode'SS-'has been prepared, Vthen the body of such electrode-'will be ia'de yfrorn hot'only the fibers Tincluded in such original ssupensions but with porous lmetal*structure-obtained 'when the originalrnetal'partioles 'are fused together into bonded'conductiverelationship ywith each other" by the heating orUsinter-ing lact-ion `performed thereon.

*InffFigf 7, -an'electrodeffstrip 701i's shown,l wherein ceramic -fibers 71 arel bonded't-ogether by -aporousmeta-l pa-rticulate conductive metalfbodyy 72,v whichi electrode could-"be" produced vbythe-frnetlcadrdisclosedin Fig. *1,- by omitting the spraynozzle Vv`16E yandf-the"porous spray metal gepositproduced thereby. i Likewise, 'tan electrodei 73, Fig."`8, may-be produced-*bythe generalmet-hod---asdisclosed-in Fig: `1, by omittingthe-spray nozzle-16 andthe aporous .spray-metal-deposit produced thereby. The -elect'rode' 73k may be produced-by'- the general method asl ldis- 'clos'ed'in Fig. 3,A when the nozzlesV 26 and 36 farefelimi- -nated and the-resultantelectrode strip-has longitudinalk21yextendii1g cords 74 therein, whichffaid infsecuriing ceramic fibers 75 together'incombinationwith themetal 4*particles v76Y presentin `the electrode 73 and -in Contact` ing, -bonded relationship toeach other tovform means yfor A"securing the'cords 74. and fibers 75 together.

f Fig. 9 shows a slightly different-type 'of' a'c-omposite lstructure, wherein a porousmetal layer 77'is provided, which layer isbondedto a ceramic fiber layer `"78. This ltype of a structure could be'produced byaapparatus as shown in Fig. 12 of the drawings and described hereinlafter, or'it may beforrnedv in accordance'withthe method :is-'indicated in Fig.y l and'wher'ein the inductive heating v'coil -1'2'wil1 be fmoved to a t'op' portion of 'thedrum 7 *andy metallic particles would Ibe' deposited'on the fibrous fmat'prduc'ed -on the drum-s v7 below the-surface vof ythe suspension' 2. There would 'be no fs'p'ray nozzle 16 required, andthe high'frequency heating-action'shouldbe suicient -to fuse `or=siriter the metalzparticles 'together rand bondthem to each vother 'and to the fibrous mat on the surface of thedrum, so'fthat'an-integral, self-sup- .porti'ngelectrode stripcan be produced therefrom.

'I'Aspecial electrode strip 79 i's shown in Fig. 10 and it comprises a porous metal center structure or-strip 84) with a surface layer of `dielectricceramic fibers $1 -b'eing -integrally bonded to each of theop'posed surfaces of thismetal layerfStiso that a porous metalstructureis provided that has spacers therefor `integrallyf-bonded thereto. The layers of dielectric fibers may preferably 'par llel"fibers'fmayfbef bonded inside 'the metal-layerV 80. 'fEig y'1lfl-showsyet a ditierentftype -rfwan-relectrodeil,

whereinsH acentrall porous, particulate metals `body: layer 83fisprovided-and ithas:afbrousidielectrio surface layer 84v bonded to eachx surface thereof. These vfibrousv layers 84'; bothzzhave 'longitudinally extending reinforciugcords 85=inflater`ally spacedfportions thereof.

Fig. l2 shows .yetfanother modicationof the method i and apparatus of the invention, lwherein-1a continuous porous Lor screen beltwhich .is made lfromfvitreou's or fibrous lor :textile gauze ymaterial :not affected-by ordinary f heating operationsis -le'dy over the. surfacewof rafpapermaking type ofescr'een drum T91 and vinto a. suspension offthe'rcera'mic iibersr'92. 'As 'inthe apparatusieferred to' before, fibers from thefs'uspension-'QZ'will be deposited on the-surface ofthe drum 911and -suitablezheatingmean's 93,. are positioned adjacert'the surface.- of the-suspension y 92 Yfor drying theabrosmatefon :thesurface of .the tdiamr '91'as it moves;ffrom, the: suspension f 92. j'lhereaften, thelbelt 90 preferably: isfsmoved from' 'the surface". ofithe metal .particles 'niaylifbe` retained and. be: fe'dauniforlly therefrom forifbuilingl up sa .desired uniform thickness, even v:layer ofrrn'et'al parti'clesion'thefbrous mat 'on the --in'rwvhich ceramicrtiberssmaybe fre'ceived and be suitably fagitatedft-hereiwas' by a'vibrator 96 so. that {such-fibers can -be' deposited `in awunifonn thickness.` l'ayer'onuthe upper surface `of the 'metal particlesfpreviously deposited onthefbelt'90. The-belt 190 th'enpasse's 'adjacent-itam Y.

rhi'gh'rfrequ'ency heating coil"`97whieh.fis suppliedfwith 'aiffsuitable source of -high 'ffrequency electrical1 energy so thatethefrmetalfparticleswvhichtare deposited lbyf the hopper 94ica`n=.=be`'sinteredrland/orv fused to eachother tcrformlra :conductive,f.` :porousilayersther'efrom, `land to bondatheitbrous ilayers unborn-surfaces o'frfsuch rn'ie'tl '.fibersimay have 'the reinforcing "cord 'eitherpositiond under the iibrous layer,` fin 'fthe' y"iibrous Alayeryori o'ntop offshoh fibrous layer, depending -upon the time at'lvwhi'ch tlie 'cords'x22 `arefbrought into contact with they surfa'dcs "of :the drum V24,v when .referring to thel embodimentif therinvention'shownlin Fig.' 3. Preferably, these-prl th'at 'is directly bonded vtothe sintered or spray-deposited porous metal layer built Yup *on thelbrous layerlto' forrn an electrode therefrom.

l'ltlwill .be realized 'thatbyuse of refractory vitreous i 'way when in normal operation iand when""subjecte`d`t'o corona "or scintillation orarcing actions 'oreffects i'Thu's,

the electrode strips will have good operative character# isticsV and properties-and ywill 'not breakdo'wn 4easily l The addition of the parallel cords ytol the accretedlyer a by. particulate metal bonding increases the vstrengtnf the strip to all desired llimitsin-.use due to thefusedfttachment of the metal particles Ato ythe accre't'edliibers and` to theparallel cords. The purity lof the efrac'toy fibers initially is advantageous in that theywntinfa fminimum. tof conductive. .particles and their ""di'e'letfic of the drawings.

strength is uniform and they are the most inert refractory fibers available to electrolytes. l 1

` One particularly desirable method of forming an electrode is by the general process disclosed in Fig. 3, wherein the longitudinally extending yreinforcing cords would be embedded in the fibrousmat produced on the surfaces of theV drum 24. In such-instances, no metallic parv ticles would be present in the suspension 21, wherein the spray nozzle 26 is used to produce a porous metal layer on only one side of the fibrous mat. The porous metal layer should be narrower in width than the fibrous layer, and the composite electrode strip would not be subjected to the lamination action of the suspension 31. Thus, the strip 28 would pass directly to a windup roll from the screen drum 24. By making the fibrous mat or layer wider than the coherent metallic layer, good edge spacing is provided in the resultant electrode which is' of unitary construction and has its'separator as an integral part thereof. The assembly of the electrode into the end item is facilitated by superimposing the dielectric fibrous layer onto a porous conductive metallic layer due to the unitary nature of the separator and porous electrode.

It may be desirable in some instances to take two electrodes of the general type shown in Fig, 9, and preferably wherein reinforcing cords have been included in the fibrous layer of the electrode, and place the metal layers of the two electrodes into face-to-face or contacting relationship. Then the laminated electrode could be passed to suitable welding means, either of the roller or spot type, in order to Weld the two metal layers together, so that a high capacity, high strength electrode could be produced and which would be covered with fibrous dielectric material on the exposed outside surfaces thereof.

The invention also may be used to make a composite electrode from particles of titanium by bonding particulate titanium to a fibrous layer such as can be produced by use of the drums 7 or 24 in Figs. l and 3 The 4titanium particles would be deposited upon this fibrous layer and usually the metal particles would then be subjected to a sintering action, preferably in non-reactive argon atmosphere, to bond the metal particles to each other and to the fibrous mat or base layer. This sintering temperature for titanium would be about 1000 C. and the ceramic or glass fibers used in the base must be made from suitable materials, as described hereinbefore, and which are not affected permanently by exposure to such temperatures.

If an impervious strip is to be produced, the particulate metal layer in the strips can be completely fused by suitable H. F. inductive heating, so that an impervious metal layeris produced and such layer is intimately bonded to the fibrous layer.

This is a continuation-in-part of my co-pending application, Serial No. 249,525, now Patent 2,757,426.

While several complete embodiments of the invention have been disclosed herein, it Will be appreciated that modification of these particular embodiments of the invention may be resorted to without departing from the scope of the invention as defined in the appended claims.

I claim:

1. A method of making continuous fibrous strip or the like comprising continuously suction-depositing refractory pulp fibers from a fluid suspension thereof to build a continuo-us porous mat therefrom on a former, and continuously spraying molten conductive particles onto the strip on the former to solidify thereon and therein to bond the fibers together into a self-supporting conductive strip and thereafter continuously removing strip from the former.

2. A method of continuously making a fibrous strip or the like comprising continuously suction-depositing dielectric fibers from a fluid suspension thereof to accrete a continuous porous mat on a former ladvancing through the slurry, and spraying a` particulate porous metal layer on the fibers thereon to bond the fibers together into a.

self-supporting strip and removing said so bonded strip .from said former.

V 3. A method of continuously making a porous particulate conductive composite strip comprising continuously drawing `a plurality of parallel cords made from dielectricmaterial through a suspension of pulp fibers, continuously suction depositing pulp fibers on `the cords to build a porous mat therefrom, continuously spraying molten metal particles onto one side ofthe mat to provide a conductive porous metal coating thereon,` depositing additional pulp fibers on the sprayed surface of the strip, and spraying molten metal particles on such second layer of pulp fibers to provide a porous metal coating thereon.

4. A method of making a porous particulate conductive composite strip comprising continuously depositing high melting temperature vitreous fibers to build a porous mat therefrom, continuously spraying molten metal particles onto the mat to provide a porous conductive metal coating thereon Iand to bind the fibers together into a strip, depositing additional vitreous fibers on the unsprayed surface of the strip, and spraying molten metal particles on such second layer of fibers to provide a porous conductive metal coating thereon bonded to the additional vitreous fibers and the first metal coating wherein the second sprayed conductive metal coating is in electrical conductive relation to the first sprayed conductive metal coating.

5. A method of making a porous particulate conductive composite strip comprising drawing a plurality of parallel cords made from dielectric material through a suspension of pulp fibers, suction depositing pulp fibers on the cords to build -a porous mat therefrom, spraying molten metal particles onto 'one side of the mat to provide a porous conductive metal coating thereon, and to make a strip therefrom, depositing additional pulp fibers on the sprayed surface of the strip, and spraying molten metal particles on such second layer of pulp fibers to provide a porous conductive metal coating thereon.

6. A method of making an electrode for an electrolytic condenser, or the like, comprising drawing a plurality of non-conductive cords over a rotating foraminous drum through a suspension of refractory pulp fibers, suction depositing refractory pulp fibers on the cords while on said drum to build a porous mat therefrom, and spraydepositing metal particles onto one side of the strip to provide a porous metal coating thereon.

7. A method of making a porous, particulate conductive composite strip, comprising positioning a plurality of non-conductive cords in longitudinal alignment in the form of a tube, drawing the cords through a refractory fiber suspension and accreting fibers thereon, and there after depositing molten metal particles on the fibers to provide a porous conductive metal layer bonded to the bers and cords.

8. A method of making a dielectric strip comprising positioning a plurality of non-conductive cords in longitudinal alignment, continuously drawing the cords through `a refractory dielectric fibrous suspension and depositing a layer of fibers thereon, and depositing molten particles on the fiber deposition to solidify such particles in and on the fibers and cords to bond. them together.

9. A method of continuously producing conductive fibrous strip material comprising attaching a layer of stranded fibrous non-conductive textile material to an accreted layer of dielectric refractory fibers by spr-ay depositing molten metal particles on and through the stranded fibrous textile material superimposed on the layer of fibers whereby the molten metal particles bond the textile layer and the accreted fibrous layer together.

(References on following page) 

2. A METHOD OF CONTINUOUSLY MAKING A FIBROUS STRIP OR THE LIKE COMPRISING CONTINUOUSLY SUCTION-DEPOSITING DIELECTRIC FIBERS FROM A FLUID SUSPENSION THEREOF TO ACCRETE A CONTINUOUS POROUS MAT ON A FORMER ADVANCING THROUGH THE SLURRY, AND SPRAYING A PARTICULATE POROUS METAL LAYER ON THE FIBERS THEREON TO BOND THE FIBERS TOGETHER INTO A SELF-SUPPORTING STRIP AND REMOVING SAID SO BONDED STRIP FROM SAID FORMER. 